Monitoring worker movement in a warehouse setting

ABSTRACT

Systems and methods for monitoring worker movement within a warehouse setting are provided. According to one implementation, a wearable apparatus comprises an audio unit configured to receive audio input signals from a user and convey audio output signals to the user. Also, the wearable apparatus includes a step count unit configured to detect walking movements of the user.

FIELD OF THE INVENTION

The present invention relates to the process of picking, or retrieving, items from a storage area.

BACKGROUND

Generally speaking, warehouses and other similar storage facilities typically include an organized network of racks and shelves on which goods are stored. When a purchasing or shipping order is received, a picker travels throughout the warehouse to retrieve the item or items listed in the order. The picked items can then be packed, if needed, and then delivered to a customer.

An organizational system is normally used in such a storage facility to identify the inventory items and the location of those items within the facility. Often, information associated with the location of inventory items is displayed in the aisles and on the shelves or racks where the items are stored. In order to correctly pick an item, the picker can match information that corresponds to the inventory item with information on the order.

Although the traditional paper-based order picking technique has been somewhat successful over the years, research has found that more efficient ways of picking have been utilized. Also, the occurrence of errors with paper-based picking is higher than more recently developed techniques. As a result of picking errors, incorrect items may be shipped to customers, leading to inventory inaccuracies and other problems. Also, extra time is needed to correct any issues, which is an unproductive use of personnel time. Furthermore, incorrect picking may also lead to customer dissatisfaction. Therefore, companies strive to improve the order picking process to increase efficiency and accuracy of their inventory handling operations.

A significant improvement in order picking includes voice-directed picking. Voice-directed picking is a method that uses verbal instructions for directing the picker to pick the correct items. Voice-directed picking typically involves a headset worn on the head of the picker and a portable computer device clipped to the picker's belt. The headset provides verbal instructions to the picker, which frees the picker's hands and eyes to easily see and pick up the proper items without the need to carry stacks of papers, clipboards, barcode readers, and other cumbersome objects used in other types of picking processes.

In addition, the headset may include a microphone that allows the picker to provide feedback to confirm that the correct item is being picked. For example, the picker may read back some of the information related to the product being picked, such as a number of “check digits.” One issue that may cause picking errors using voice-directed picking, however, is that a picker might memorize the check-digits for some of the more common items and attempt to speak the check digits from memory.

Therefore, a need exists for improving the way in which items are retrieved or picked from a warehouse or storage facility. The present invention provides systems and methods that improve upon the voice-directed item-picking processes already in existence in order to attempt to improve efficiency and further reduce the number of picking errors.

SUMMARY

Accordingly, in one aspect, the present invention embraces a workflow system comprising a plurality of audio-based picker devices. Each audio-based picker device is configured to be worn by a respective user and configured to enable two-way audio communication with the respective user. The workflow system further comprises a host computer configured in wireless communication with the plurality of audio-based picker devices. The host computer is configured to determine a workflow process for each user. Each audio-based picker device includes an inertial unit configured to calculate a step count related to walking movements of the respective user. Furthermore, each audio-based picker device is configured to communicate the workflow process to the respective user based at least on the calculated step count.

In another exemplary embodiment, a wearable apparatus is disclosed. The wearable apparatus includes an audio unit configured to receive audio input signals from a user and convey audio output signals to the user. The wearable apparatus also includes a step count unit configured to detect walking movements of the user.

In yet another exemplary embodiment, a workflow method is provided. The method includes the steps of determining a workflow process for a user, the workflow process including a number of workflow operations. The method also includes transmitting a first workflow operation to a communication unit associated with the user for conveying the first workflow operation to the user. A step count is received from the communication unit associated with the user, the step count being related to walking movements of the user. An audio signal is received from the communication unit associated with the user, the audio signal including verbal responses from the user. The method further includes the step of determining whether or not conditions of the first workflow operation have been met based on the step count and the verbal responses.

In another aspect, the present invention embraces a workflow system that includes at least one audio-based picker device, configured to enable two-way audio communication with the respective user, and a host computer in wireless communication with said at least one audio-based picker device. Typically, the host computer is configured to determine a workflow process for the user, the at least one audio-based picker device includes an inertial unit configured to calculate an estimated distance corresponding to movements of the respective user, and the at least one audio-based picker device is configured to communicate the workflow process to the respective user based at least on the calculated step count.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating an audio-based picker device according to various embodiments of the present invention.

FIG. 2 is a block diagram illustrating the circuitry included in the audio-based picker device of FIG. 1 according to various embodiments of the present invention.

FIG. 3 is a diagram illustrating a warehouse management system (WMS) according to various embodiments of the present invention.

FIG. 4 is a diagram illustrating a section of a storage area according to various embodiments of the present invention.

FIG. 5 is a flow diagram illustrating a method of executing an item-picking process according to various embodiments of the present invention.

DETAILED DESCRIPTION

The present invention is directed to systems and methods for assisting a picker in the process of picking inventory items from a storage area. Recently, voice-assisted picking has been developed in the field of inventory management to increase efficiency and to reduce errors in the handling of items stored within a warehouse or other storage facility. In addition to providing verbal instructions to the picker and receiving verbal responses from the picker, the present invention is also configured to monitor movement of the picker.

In order to prevent a picker from simply reciting check digits from memory, the movement monitoring system counts the picker's steps to determine if the picker has actually moved to the correct location to pick the items. When a predetermined distance has been calculated to allow the picker to move to the appropriate location where the next pick is to be made, then the system will allow the picker to read the check digits for that item. Otherwise, if the measurement of the picker's movement does not reach or exceed the predetermined minimum amount, then the system detects an error and instructs the picker to move to the correct pick location.

FIG. 1 is a diagram showing an embodiment of an audio-based picker device 10, which is configured as a portable device to be carried or worn by a picker. According to the embodiment shown in FIG. 1, the audio-based picker device 10 includes a headset 12 and a portable computing device 14. The headset 12 and portable computing device 14 may be connected together by way of a cable 16. In other embodiments, the headset 12 and portable computing device 14 may communicate with each other using a wireless communication protocol, such as Bluetooth™. In the case of wireless communication, the cable 16 can be omitted, thereby eliminating any possibility of an intermediate cable interfering with the picker's arms or hands.

The portable computing device 14 includes a first connector 18, or interface, for coupling with the cable 16. The portable computing device 14 may also include at least a housing 20 and a number of user interface elements. The user interface elements may include, for example, a display unit 22, visual output elements 24 (e.g., LEDs), and input elements 26 (e.g., keypad, buttons, etc.).

The headset 12 includes one or more audio output devices 30 (e.g., headphone speakers), audio input device 32 (e.g., microphone), one or more support straps 34, and support pad 36. The headset 12 may be used in a voice-directed picking process for enabling a user (i.e., the picker) to receive audible picking instructions and to respond with voice commands.

The headset 12 may be worn on the head of the picker in a conventional manner such that the audio output device 30 is next to the picker's ear or ears and the audio input device 32 is near the front of the picker's mouth. The portable computing device 14 may have a clip, clamp, or other suitable fixing unit (not shown) for attaching the portable computing device 14 to the picker's belt, clothing, a pocket of the picker's clothing, a waistband, or other article of clothing or accessory.

The portable computing device 14 may include voice recognition software for converting speech to text and voice synthesizing software for converting text to speech. Also, the portable computing device 14 may include picking assistance software to be used in cooperation with the headset 12, allowing the portable computing device 14 to provide audible picking instructions to the picker and receive audible responses from the picker.

According to the teachings of the present disclosure, the portable computing device 14 may further include step count software for counting the number of steps taken by the picker between picks. For example, if the warehouse management system knows the approximate distance from one location where a first item is located in the warehouse to another location where a next item is located, then an approximation can be made regarding the number of steps that a picker would have to take to travel from the first location to the next one. If the step count is too low for a picker to possibly travel the needed distance, then an error is detected. The system may determine that the picker is reciting check digits from memory without actually moving to the required location to retrieve the items or that the picker is simply in the wrong location.

The portable computing device 14 may be configured to store a list of items to be picked by the picker. For example, using wireless communication in the general vicinity of a warehouse computer, the portable computing device 14 may receive the item list and store it in memory. Using voice software, the portable computing device 14 may provide instructions to the picker regarding information related to the first item to be picked. The instructions may be shown on the display 22, may be audibly expressed through the audio output device 30 using voice commands or tonal commands, or may be indicated in other suitable ways. The instructions may include the name of the item to be picked, a product number, check digits, or other reference characters corresponding to the item, a location of the item, directions of how the picker is to get to the item's location, etc.

FIG. 2 is a block diagram illustrating an embodiment of circuitry of the audio-based picker device 10 of FIG. 1. In some embodiments, the circuitry may be contained completely within the headset 12, in which case the portable computing device 14 may be omitted. In other embodiments, some of the circuitry shown in FIG. 2 may be housed in the headset 12 while some of circuitry may be housed in the portable computing device 14. In still other embodiments, some elements may be housed in both the headset 12 and portable computing device 14.

The audio-based picker device 10, according to the embodiment shown in FIG. 2, includes a processing device 40, a memory device 42, audio input unit 44, audio output unit 46, a wireless communication device 48, and an inertial device 50. The processing device 40 is configured to control the operations of the audio-based picker device 10 and is configured to receive input signals from and provide output signals to the other components of the audio-based picker device 10. It should be noted that the audio-based picker device 10 may include additional components, such as a power source, input devices, output devices, and other components, as would be known by one of ordinary skill in the art.

The processing device 40 may include one or more processors, microprocessors, central processing units, digital signal processors, or other electronic processing components. The processing device 40 may communicate with the other components of the audio-based picker device 10 via one or more bus interfaces.

The memory device 42 may include any combination of volatile and non-volatile memory elements for storing software, data, commands, etc. Picking software may be stored in the memory device 42 for assisting the picker with the picking process, as explained herein. The picking software may be stored on a non-transitory computer-readable medium. According to various embodiments, picking programs may be stored in software, firmware, and/or hardware and executed by the processing device 40.

The inertial device 50 is configured to measure inertia related to the movements of the picker. For example, according to some embodiments, the inertial device 50 may include an acceleration module 52 and a gyroscopic module 54. The acceleration module 52 may include one or more accelerometers and the gyroscopic module 54 may include one or more gyroscopes. According to various embodiments, the acceleration module 52 and gyroscopic module 54 may be incorporated either in the headset 12 for detecting the movements of the picker's head or in the portable computing device 14 for detecting the movements of the picker's body. The accelerometers of the acceleration module 52 may include electromechanical devices for measuring acceleration forces in an x-axis, y-axis, and z-axis with respect to the audio-based picker device 10. The gyroscopes of the gyroscopic module 54 may also include electromechanical devices for measuring angular velocity with respect to the x, y, and z axes.

Among other things, the picking software may include a step count module 56, a voice recognition module 58, and a voice synthesizing module 60. The step count module 56 may be used to analyze the data obtained by the acceleration module 52 and gyroscopic module 54 to determine the steps taken by the picker between two sequential picking locations.

Based on acceleration data, not only can the step count module 56 determine the number of steps taken, based on the rhythm of the walking motion, but the step count module 56 can also determine the walking velocity. For example, based on a certain acceleration in one direction for a certain amount of time, the processing device 40 may utilize the step count module 56 to calculate a velocity. Also, when a deceleration, or acceleration in the opposite direction, is detected, the velocity can be recalculated to determine when the picker comes to a stop. Also, a rest condition can be determined by measuring no additional net acceleration forces over a certain length of time.

The voice recognition module 58, which may be stored in the memory device 42, is configured to receive speech from the picker and convert that speech into text. The text can then be processed by the audio-based picker device 10 and/or transmitted to a warehouse computer that manages the audio-based picking process. Conversely, the voice synthesizing module 60 is configured to receive text signals from the memory device 42 or from the warehouse computer and convert the text into speech, which is conveyed to the audio output unit 46 for providing verbal instructions to the picker. The voice recognition module 58 and voice synthesizing module 60 may be calibrated for a particular user depending on the preferred language, speech patterns, dialect, and other characteristics of the user's speech and preferences.

FIG. 3 is a diagram showing an implementation of a warehouse management system 64. The warehouse management system 64 includes a host computer 66, or warehouse computer, and a plurality of audio-based picker devices 10. The audio-based picker devices 10, which are described above with respect to FIGS. 1 and 2, are carried or worn by a plurality of pickers as they move throughout the warehouse. The host computer 66 provides customized instructions to each of the audio-based picker devices 10 depending on the item-picking routines that each particular picker is needed is follow.

When a picker is within range of the host computer 66, the host computer 66 transmits an item list to the picker's audio-based picker device 10. For example, the wireless communication device 48 of the respective audio-based picker device 10 (see FIG. 2) may be used for communicating with the host computer 66. The item list may include one or more items to be picked. The item list may also include information regarding any product numbers corresponding to the items, the quantity of each item to be picked, the location of the items, etc. When the list is received, the picker can then travel throughout the warehouse to retrieve the items. In some embodiments, audio instructions are provided to the picker to direct him or her to the location of the items.

According to various alternative embodiments, the audio-based picker device 10 may also receive and store distance information from the host computer 66. The distance information may include the approximate distances between each of the subsequent pick locations. These stored distances can then be used to compare with step count information obtained by the audio-based picker device 10 to determine if the picker has traveled the required minimum distance to get to the correct picking location. Therefore, instead of communicating step information back to the host computer 66, as mentioned above with respect to other embodiments, the step count information can be analyzed by the audio-based picker device 10 itself.

FIG. 4 is a diagram showing a small section 70 of a warehouse or other storage facility according to an exemplary embodiment. FIG. 4 shows a rack structure 72 having vertical supports 74 and horizontal shelf units 76. Bins 78 may be placed on the rack structure 72 for storing a number of small inventory items. Other inventory items, such as those having an easily stackable configuration, may be placed directly on the horizontal shelf units 76.

In addition, the rack structure 72 may further include product sheets (not shown) that describe the items in detail and may also include tags 80 or other signage elements for displaying a number of check digits. The check digits may be used to designate a certain area or section 70 of the warehouse or may be used to designate certain items or families of items.

As shown as an example in FIG. 4, the check digits on the tags 80 include different numbers, which may be dependent on any arbitrary warehouse organizational system. In the illustrated example, numbers 255104, 255105, 255106, 255107, 255108, and 255113 are shown on tags 80 and may represent a particular warehouse numbering system to identify different inventory items stored in the various bins 78. It should be noted that the check digits may be different for different warehouses based on any particular organizational technique. The check digits may not necessarily be sequential or in numerical order, as shown, but may depend on the particular organizational system being used in the particular warehouse.

The tags 80 may be placed on any combination of the vertical supports 74, horizontal shelf units 76, and/or bins 78. The tags 80 may be adhered using any suitable adhesion material, such as glue, tape, Velcro, etc., for attaching to the rack structure 72.

FIG. 5 shows an embodiment of a method for controlling a picking process for a single picker during a shift. The method may be performed by the host computer 66 shown in FIG. 3, by the processing device 40 of the audio-based picker device 10 itself, or by another controlling device in the warehouse.

The picking method includes the steps of determining a first item to be picked, as indicated in block 90. The item to be picked can be selected from a group of items to be picked by a single picker during a shift. According to block 92, the method includes determining an approximate distance that the picker must travel to get to the location of the first item. The calculated distance may be obtained from information regarding the location of the inventory items in the warehouse and the starting location of the picker.

The method also includes the step of instructing the picker regarding the location of the first item. The instructions may include warehouse section information, aisle numbers, etc. Also, the instructions may include suggested directions for getting the picker to the proper location in the shortest time possible. When the picker arrives at the picking location, the picker may send a signal indicating that the location has been reached. As indicated in block 96, the host computer 66 receives a notification from the picker device that the picker intends to provide check digits to verify that the picker is indeed at the proper location for picking the first item. After providing instructing according to block 94, there will be a certain amount of time that will elapse before the picker can move to the location to provide the notification according to block 96. This time may also be taken into account.

When the notification according to block 96 is sent from the picker device, the picker device also calculates the step count from a starting point to a current location. The system (e.g., host computer 66) receives the step count information from the picker device, as indicated in block 98. In some embodiments, at least a part of the calculations of step count can be performed by the host computer 66 itself and may include receiving certain information, such accelerometer and gyroscope measurements, from the picker device.

According to decision block 100, the method of FIG. 5 further includes determining if the step count is greater than a minimum threshold that would be needed to cover the approximate distance calculated in step 92. The threshold value may be based on warehouse distance information, time information, approximate stride length of the picker, and other factors that may limit the necessary time and steps that can be achieved by a picker.

If the step count is not sufficient to cover the approximate distance, it can be determined that the picker has not moved to the proper location to pick the first item. In this case, the method proceeds to block 102, which indicates that the system instructs the picker to move to the proper location in order to make the pick. The system may also signal that an error has occurred and transmit the error signal to the picker or to another device, if needed. After this, the method returns back to block 94 to repeat several steps as needed. Otherwise, if it is determined in decision block 100 that the step count is sufficient to cover the distance, the method proceeds to block 104.

The method performs the step indicated in block 104 after it is determined that the picker has moved at least to a location where the first item is located. Therefore, it can be determined that the picker will not simply be reciting check digits from memory without moving from an original starting point. Block 104 indicates that the method further includes receiving check digits from the picker. According to some embodiments, the picker may read the check digits in response to a prompt or after indicating in some other manner that the check digits are to be read.

The method further includes the step of determining, according to decision block 106, whether or not the check digits read by the picker are correct. If not, then the method returns back to block 94 to correct any mistakes that may have been made in the picking process. In some cases, the picker may have misread the check digits and simply needs to read the check digits again.

If it is determined in decision block 106 that the check digits are correct, then it can be determined that the picker is in the correct position for making a pick. At this point, the method proceeds to block 108, which includes instructing the picker to pick a certain quantity of items as needed in the order. After making a successful pick, the system determines, according to decision block 110, whether or not there are more items to be picked. If not, then the picking process ends. However, if more items are to be picked, the method loops back to the beginning and repeats the picking process for the next item to be picked. Also, it should be noted that the step count in the host computer 66 and in the picker device 10 may be reset at this point in order to allow detection of a new step count from the location of the previous pick to the location of the next pick. Also, the distance determined in block 92 may be calculated based on the location of the next pick with respect to the current location regarding the previous pick.

To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation. 

1. A workflow system comprising: at least one audio-based picker device, configured to enable two-way audio communication with the respective user; a host computer in wireless communication with said at least one audio-based picker device; wherein the host computer is configured to determine a workflow process for the user; wherein the at least one audio-based picker device includes an inertial unit configured to calculate an estimated distance corresponding to movements of the respective user; and wherein the at least one audio-based picker device is configured to communicate the workflow process to the respective user based at least on the calculated step count.
 2. The workflow system of claim 1, wherein the calculated estimated distance is an estimate step count of the user.
 3. The workflow system of claim 1, wherein the at least one audio-based picker device includes an audio unit configured to receive verbal responses from the respective user and transmit the verbal responses and the estimated distance to the host computer.
 4. The workflow system of claim 1, wherein the inertial unit of the at least one audio-based picker device includes at least one accelerometer configured to measure acceleration forces along an x-axis, a y-axis, and a z-axis.
 5. The workflow system of claim 4, wherein the inertial unit of the at least one audio-based picker device further includes at least one gyroscope configured to measure angular velocity about the x-axis, y-axis, and z-axis.
 6. The workflow system of claim 5, wherein the inertial unit of the at least one audio-based picker device further includes a step count module configured to calculate a number of steps taken by the user based on measurements from the at least one accelerometer and at least one gyroscope.
 7. The workflow system of claim 1, wherein the at least one audio-based picker device is configured to convey a first set of audio output signals to the user when a step count is below a predetermined threshold and to convey a second set of audio output signals to the user when the step count is above the predetermined threshold.
 8. A wearable apparatus comprising: an audio unit configured to receive audio input signals from a user and convey audio output signals to the user; and a step count unit configured to detect walking movements of the user.
 9. The wearable apparatus of claim 8, wherein the wearable apparatus is disposed at least partially in a headset to be worn on the head of the user.
 10. The wearable apparatus of claim 8, further comprising a wireless communication module configured to communicate wirelessly with a host computer.
 11. The wearable apparatus of claim 10, wherein the wireless communication module is configured to receive workflow steps from the host computer, and wherein the audio unit is configured to verbally convey the workflow steps to the user.
 12. The wearable apparatus of claim 10, wherein the audio unit is configured to receive verbal responses from the user, and wherein the wireless communication module is configured to transmit the verbal responses and the detected walking movements to the host computer.
 13. The wearable apparatus of claim 8, wherein the step count unit includes at least one accelerometer configured to measure acceleration along an x-axis, a y-axis, and a z-axis.
 14. The wearable apparatus of claim 13, wherein the step count unit further includes at least one gyroscope configured to measure angular velocity about the x-axis, y-axis, and z-axis.
 15. The wearable apparatus of claim 14, wherein the step count unit further includes a step count module stored in a memory device, the step count module enabling a processing device to calculate a number of steps taken based on measurements from the at least one accelerometer or at least one gyroscope.
 16. The wearable apparatus of claim 8, wherein the audio unit conveys a first set of audio output signals to the user when the walking movements are below a predetermined distance threshold and conveys a second set of audio output signals to the user when the walking movements are above the predetermined distance threshold.
 17. A workflow method comprising the steps of: the workflow process including a number of workflow operations; transmitting a first workflow operation to a communication unit associated with the user for conveying the first workflow operation to the user; receiving a step count from the communication unit associated with the user, the step count being related to walking movements of the user; receiving an audio signal from the communication unit associated with the user, the audio signal including verbal responses from the user; and determining whether or not conditions of the first workflow operation have been met based on the step count and the verbal responses.
 18. The workflow method of claim 17, wherein the conditions of the first workflow operation are met when the step count is above a predetermined threshold value and when the verbal responses include correct check digits. 